System and method for straightening tubing

ABSTRACT

A technique enables extending the useful life of tubing deployed in a wellbore. The technique involves routing a damaged or distorted tubing through a straightening device. The tubing straightening device bends and counter bends the tubing along predetermined axes as it passes through the tubing straightening device. The bending and counter bending are selected so the tubing exits the straightening device with a predetermined form.

BACKGROUND

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. In many types of well related operations, various types of tubing are deployed downhole into a wellbore. Smaller diameter tubing, e.g. control lines, may be used in conjunction with larger diameter tubing, e.g. production or coiled tubing. For example, control lines may be deployed within or along a coiled tubing string to facilitate the transmission of signals along the wellbore. In some applications, control lines utilize a carrier tubing for enclosing a signal carrier, such as an optical fiber. However, many of these types of tubing are susceptible to being bent or otherwise deformed during operations and/or during movement into and out of the wellbore. If sufficiently bent or otherwise damaged, the tubing may not be available for reuse.

SUMMARY

In general, the present disclosure provides a system and method for extending the useful life of tubing deployed in a wellbore. Initially, a damaged or distorted tubing is selected, and the tubing is routed through a straightening device. The tubing straightening device bends and counter bends the tubing along predetermined axes as it passes through the tubing straightening device. The bending and counter bending are selected so the tubing exits the straightening device with a predetermined form, e.g. a straightened form.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain embodiments of the invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:

FIG. 1 is a schematic illustration of one embodiment of a tubing straightening device;

FIG. 2 is a schematic illustration similar to that of FIG. 1 but with additional features;

FIG. 3 is a schematic representation of a bending regimen useful in straightening certain types of tubing;

FIG. 4 is an illustration of one embodiment of a straightening station wheel acting on tubing passing through the tubing straightening device; and

FIG. 5 is a flowchart providing one example of a procedure which may be employed to straighten tubing with the tubing straightening device.

DETAILED DESCRIPTION

In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those of ordinary skill in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.

The present disclosure generally relates to a system and method for extending the useful life of certain types of tubing employed in downhole applications. For example, the technique enables returning control line tubing, e.g. fiber carrier tubing, to a form which allows continued use in subsequent downhole applications. In many well related operations, deployment and use of tubing downhole creates bends or other distortions in the tubing, and those distortions can be substantially removed by employing the methodology described herein.

In one embodiment, a tubing straightening device is used to return a distorted length of tubing to its original shape by re-straightening the distorted length of tubing. The technique may be designed to correct many types of distortions in several types of tubing, e.g. control line tubing. One embodiment employs the tubing straightening device to straighten optical fiber carrier tubing, such as fiber carrier tubing formed from Inconel™ or from a variety of other materials, including other metal tubing materials. Once straightened, the fiber carrier tubing can be reinjected into a coiled tubing string and reused as opposed to purchasing a new spool of fiber carrier tubing for injection into the coiled tubing string.

According to one application, the tubing straightening device comprises a series of stations mounted along a rigid chassis. Each of the stations is designed to bend the tubing in a direction along a predetermined axis as the tubing is moved through the tubing straightening device. In one specific embodiment, the series of stations comprises a series of roller or wheel sets which subject the tubing to a sequence of bending cycles and cause the tubing to straighten before exiting the tubing straightening device. The series of wheel sets may comprise a series of four wheel sets which bend and counter bend the tubing along two distinct axes, e.g. a Y-axis and an X-axis. The wheel sets are adjustable to bend and counter bend the tubing in the desired sequence of directions regardless of how the tubing enters the tubing straightening device. In some applications, the final two wheel sets are employed to “set the bend” which results in a straight tube upon exit.

Referring generally to FIG. 1, one embodiment of a system 20 for straightening a tubing 22 is illustrated. In this embodiment, system 20 comprises a tubing straightening device 24 which returns the tubing 22 to a desired form as the tubing 22 is passed through device 24. By way of example, tubing 22 enters the tubing straightening device 24 as a distorted, e.g. bent, tubing (as represented by reference character 26) and exits tubing straightening device 24 in a desired form, e.g. a straight tube (as represented by reference character 28). The tubing 22 may be control line tubing, such as a communication line carrier. In one embodiment, tubing 22 is a small diameter communication line carrier in the form of an optical fiber carrier tubing.

In the embodiment illustrated, tubing straightening device 24 comprises a chassis 30 having a tubing inlet 32 through which tubing 22 enters and a tubing outlet 34 through which tubing 22 exits the tubing straightening device. Tubing straightening device 24 further comprises a plurality of stations 36 which are designed to manipulate the tubing 22 in a manner that removes the undesired distortions, e.g. bends and/or remove local deformations on the tubing 22. The number, arrangement and type of stations 36 can be altered according to the type of tubing 22 being reconditioned. However, in one embodiment of the tubing straightening device 24, the stations 36 each comprise a roller or wheel set 38.

Each wheel set 38 comprises a plurality of wheels 40 through which tubing 22 is passed. The wheels 40 are positioned to bend the tubing 22 to a desired degree and in a desired direction. The desired bending at each sequential wheel set 38 may be achieved by forming at least one of the wheels 40 as an adjustable wheel 42 while the other wheels 40 are mounted in a stationary position on chassis 30. In the illustrated embodiment, the desired bending is achieved at each wheel set 38 by utilizing one adjustable wheel 42 which acts on the tubing 22 between two stationary wheels 40 as the tubing 22 is passed through that specific wheel set 38.

The adjustable wheel 42 may be moved toward or away from the cooperating stationary wheels 40 to apply a greater or lesser bending force for reconditioning the tubing 22. Movement of each adjustable wheel 42 may be accomplished by a corresponding actuator 44 which may be a manual or powered actuator. In one example, each actuator 44 is a mechanical actuator, such as a ball and screw actuator or a stepper motor actuator.

In the embodiment illustrated in FIG. 1, the actuators 44 are oriented in different directions relative to each other to apply desired bending forces to the tubing 22, via wheels 42, in corresponding directions. By way of example, the actuators 44 and wheel sets 38 may be positioned to enable bending and counter bending of the tubing 22 along a plurality of different axes. In the specific example illustrated, tubing 22 moves into the first station 36 and a bending force is applied to the tubing 22 in a direction along a first axis. From the first station 36, the tubing 22 is directed through a second station 36 which applies a bending force to the tubing 22 in a direction along a second axis, e.g. a perpendicular axis. From the second station 36, the tubing 22 is directed to a third station 36 which applies a counter bending force to the tubing 22 in an opposite direction along the first axis. Subsequently, the tubing 22 is directed from the third station to a fourth station 36 which applies a counter bending force to the tubing 22 in an opposite direction along the second axis. In this example, the sequential and controlled bending of tubing 22 creates a straight tube which exits tubing straightening device 24 through tubing outlet 34.

Movement of tubing 22 through tubing straightening device 24 may be facilitated by a feeder mechanism 46, as illustrated in FIG. 2. The feeder mechanism 46 is employed to guide the deformed tubing 26 into tubing inlet 32 of tubing straightening device 24. A puller mechanism 48 also may be used to provide a pulling force which helps move tubing 22 through tubing straightening device 24. In some applications, actuators 44 may be in the form of automated actuators controlled by a control system 50. For example, control system 50 may be a processor based control system which may be programmed to automatically adjust the actuators 44 to apply desired bending forces to the tubing 22 at each sequential station 36.

In one specific embodiment, the tubing 22 undergoes bending and counter bending in directions along both a Y-axis and an X-axis, as illustrated in FIG. 3. In this embodiment, the distorted tubing, e.g. distorted carrier tubing, is fed into tubing straightening device 24 through tubing inlet 32 and routed through the first wheel set 38. The first wheel set bends the tubing 22 in a direction along the −Y axis relatively aggressively, as represented by arrow 52. This bending action pre-forms the tubing 22 in the −Y axis direction, thereby removing any opposing Y axis residual bend it may have had before entering tubing straightening device 24. The bending at the first wheel set 38 pre-shapes the Y-axis of the tubing 22.

Subsequently, tubing 22 is routed through the second wheel set 38 between the adjustable and stationary wheels 40. The second wheel set bends the tubing 22 in a direction along the −X axis relatively aggressively, as represented by arrow 54. This bending action pre-forms the tubing 22 in the −X axis direction, removing any opposing X axis residual bend it may have had before entering tubing straightening device 24.

The tubing 22 is then routed through the third wheel set 38, which is oriented and adjusted to counter bend tubing 22 in a direction along the +Y axis, as represented by arrow 56. The tension or bending force applied by the third wheel set 38 may be somewhat less than applied by the first and second wheel sets 38. Because the residual bend of the tubing 22 is known at this point in the tubing straightening device 24, the tension/bending force applied by the third wheel set 38 is selected to neutralize the Y axis residual bend of the tubing 22.

After leaving the third wheel set 38, tubing 22 is routed through the fourth wheel set 38, which is oriented and adjusted to counter bend tubing 22 in a direction along the +X axis, as represented by arrow 58. The tension or bending force applied by the fourth wheel set 38 also may be somewhat less than applied by the first and second wheel sets 38. Because the residual bend along this axis of the tubing 22 also is known at this point in the tubing straightening device 24, the tension/bending force applied by the fourth wheel set 38 is selected to neutralize the X axis residual bend of the tubing 22. As a result, a straightened tubing 22 or 28 having a generally linear form is delivered through tubing outlet 34. The operation of the stations 36 and/or wheel sets 38 of straightening device 24 also advantageously removes local deformations from the tubing 22. The straightened tubing can be reinjected into coiled tubing or otherwise reused in a downhole application.

Although a variety of wheels, e.g. rollers, and other devices may be used to apply desired bending forces to tubing 22 in directions along predetermined axes, one embodiment of a suitable wheel 40 is illustrated in FIG. 4. In this embodiment, each wheel 40 comprises a circumferential groove 60 along its face. Groove 60 is sized to receive tubing 22 and, in some applications, maybe slightly larger than the tubing 22 being straightened (or being returned to another desired form). The groove 60 aids in maintaining the tubing 22 in a desired alignment during the straightening process.

One or more of the wheels 40 also may be used in cooperation with a shaping mechanism 62, such as a shaping wheel. The shaping mechanism 62 works in concert with the wheel 40 to provide a desired cross-sectional shape to the tubing 22. For example, the shaping mechanism 62 may be in the form of a wheel having a shaping groove 64 to correct any undesired ovality of the tubing 22. If, for example, the tubing 22 has been deformed to an undesirable oval shape, the tubing 22 may be passed along or through an appropriate shaping mechanism 62 to return the tubing 22 to a more circular cross-sectional shape. In some applications, the shaping mechanism 62 works in cooperation with one or more of the wheels 40, or is constructed as a separate opposing wheel set, to provide sufficient force for reshaping the tubing 22 and returning it toward its original round shape.

Referring generally to the flowchart of FIG. 5, one example of an operational procedure for straightening tubing, e.g. fiber carrier tubing, is illustrated. In this particular embodiment, a control line tubing 22, such as a fiber carrier tubing, is initially selected for straightening, as represented by block 66. The tubing 22 is then fed into straightening device 24 through tubing inlet 32, as represented by block 68. The tubing is moved through the first station 36 and is bent in a first direction along a first axis, as represented by block 70.

The tubing 22 is then routed through the second station 36 which bends the tubing in a second direction along a second axis, as represented by block 72. As the tubing continues to move through straightening device 24, it is routed through the third station 36 which counter bends the tubing in an opposite direction along the first axis, as represented by block 74. Similarly, the tubing 22 is passed through the fourth station 36 which also counter bends the tubing but in an opposite direction along the second axis, as represented by block 76. After the fourth station, the tubing 22 is discharged through tubing outlet 34 as a straightened tubing for reuse, as represented by block 78.

The tubing straightening device 24 may be employed to recondition and remove local deformations from a variety of tubing types for use in many well related applications. The tubing straightening device 24 is particularly amenable for use in straightening and/or removing location deformations from relatively small tubes of formable material, e.g. metallic material. For example, control lines are often formed of metal with relatively small diameters, e.g. diameters equal to or less than 0.25 inch. Fiber carrier tubing often is formed from materials that may be shaped, e.g. metal materials and metal alloys, e.g. Inconel™, having small diameters of, for example, less than 0.10 inch. In some applications, the straightening device 24 also may be employed to reconditioned tubes having larger diameters.

Additionally, tubing straightening device 24 may be constructed in alternate configurations depending on various factors, such as tubing size, tubing material, type of distortion, and desired finished form. For example, the number of stations mounted along the chassis may be adjusted to accommodate the reconditioning requirements of a given tubing. Wheels or other mechanisms may be employed to provide the bending forces used to bend the tubing along desired axes as the tubing moves through the straightening device. The tubing also may undergo bending/counter bending in negative and/or positive directions along two or more axes. Various feeders and pulling mechanisms may be used in combination with the straightening device to enable controlled movement of the tubing through the straightening device. Additionally, various types of mechanical and/or automated actuators may be used to apply the desired bending forces to the tubing at each station. In many applications, the applied bending force varies between stations and is selected according to the types of tubing and types of distortions being reconditioned.

Accordingly, although only a few embodiments of the present invention have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this invention. Such modifications are intended to be included within the scope of this invention as defined in the claims. 

1. A system for facilitating reuse of a communication line carrier, comprising: a chassis having a carrier tubing inlet and a carrier tubing outlet through which a carrier tubing passes; a first wheel set having at least one adjustable wheel which is selectively positioned to bend the carrier tubing in a first Y-axis direction after the carrier tubing enters through the carrier tubing inlet; a second wheel set having at least one adjustable wheel which is selectively positioned to bend the carrier tubing in a first X-axis direction; a third wheel set having at least one adjustable wheel which is selectively positioned to bend the carrier tubing in a second Y-axis direction generally opposite the first Y-axis direction; and a fourth wheel set having at least one adjustable wheel which is selectively positioned to bend the carrier tubing in a second X-axis direction generally opposite the first X-axis direction, wherein the degree of bending is selected such that the carrier tubing exiting the carrier tubing outlet is substantially straight.
 2. The system as recited in claim 1, wherein the carrier tubing inlet is sized to receive a fiber carrier tubing.
 3. The system as recited in claim 1, wherein the bending force exerted on the carrier tubing by the first wheel set is greater than the bending force exerted by the third wheel set.
 4. The system as recited in claim 3, wherein the bending force exerted on the carrier tubing by the second wheel set is greater than the bending force exerted by the fourth wheel set.
 5. The system as recited in claim 1, wherein each of the first, second, third and fourth wheel sets comprises three wheels in which two of the three wheels are stationary and one of the three wheels is adjustable.
 6. The system as recited in claim 1, wherein each of the at least one adjustable wheels is manually adjustable.
 7. The system as recited in claim 1, wherein each of the at least one adjustable wheels is automatically adjustable via a control system.
 8. The system as recited in claim 1, wherein each of the at least one adjustable wheels comprises a circumferential groove sized to receive the carrier tubing.
 9. The system as recited in claim 1, further comprising a shaping wheel which removes ovality from the carrier tubing.
 10. A method of extending the useful life of a carrier tubing, comprising: selecting a carrier tubing having distortions along its length; routing the carrier tubing through a tubing straightening device; and bending and counter bending the carrier tubing along a plurality of axes as it passes through the tubing straightening device until the carrier tubing exits the tubing straightening device with the distortions removed.
 11. The method as recited in claim 10, wherein bending and counter bending comprises bending and counter bending an optical fiber carrier tubing in both a Y-axis and a substantially perpendicular X-axis.
 12. The method as recited in claim 10, wherein bending and counter bending comprises routing the carrier tubing through a plurality of wheel sets, each wheel set having cooperating wheels positioned to apply a bending force to the carrier tubing.
 13. The method as recited in claim 12, further comprising adjusting at least one wheel of each wheel set to apply the desired bending force.
 14. The method as recited in claim 13, wherein adjusting comprises of adjusting the at least one wheel of each wheel set such that the bending force applied during bending is greater than during counter bending in each of the axes.
 15. The method as recited in claim 10, wherein bending and counter bending comprise substantially straightening the carrier tubing.
 16. The method as recited in claim 15, wherein bending and counter bending comprise reducing ovality of the carrier tubing.
 17. A method, comprising: bending a tubing in directions along a first axis and along a second axis as the tubing moves through a tubing straightening device; counter bending the tubing in directions along the first axis and along the second axis as the tubing moves through the tubing straightening device; and selecting the amount of bending and counter bending to provide the tubing with a predetermined form upon exiting the tubing straightening device.
 18. The method as recited in claim 17, wherein bending comprises bending the tubing in directions along a Y-axis and along an X-axis perpendicular to the Y-axis.
 19. The method as recited in claim 18, wherein counter bending comprises counter bending the tubing with less force than applied during bending.
 20. The method as recited in claim 19, wherein counter bending comprises counter bending after first bending the tubing along both the Y-axis and the X-axis.
 21. The method as recited in claim 17, wherein bending comprises bending a fiber carrier tubing with a diameter equal to or less than 0.25 inch.
 22. The method as recited in claim 17, wherein bending comprises bending a fiber carrier tubing having a diameter equal to or less than 0.1 inch.
 23. The method as recited in claim 17, further comprising injecting the tubing into a coiled tubing string and deploying the coiled tubing string in a wellbore.
 24. The method as recited in claim 17, wherein selecting comprises providing the tubing with a reduced ovality. 